INSTLLTION INSTRUCTIONS WLL MOUNTED PCKGE HET PUMPS Models SH261 SH311 Bard Manufacturing Company Bryan, Ohio 43506 Since 1914...Moving ahead just as planned. Manual : 2100-409 Supersedes: 2100-409 File: Volume III Tab 17 Date: 09-01-03 Copyright 2003
CONTENTS Getting Other Informations and Publications 1 Wall Mount General Information Heat Pump Wall Mount Model Nomenclature... 2 Shipping Damage... 5 General... 5 Duct Work... 5 Filters... 5 Fresh ir Intake... 6 Condensate Drain... 6 Installation Instructions Wall Mounting Information... 7 Mounting the Unit... 7 Wiring Main Power... 12 Wiring Low Voltage Wiring... 12 Optional Outdoor Thermostat pplications... 13 Heat nticipation... 15 Thermostat Indicator Lamps... 15 Emergency Heat Position... 15 Compressor Malfunction Light... 15 Low Voltage Connections... 15 Start Up Important Installer Note... 17 High Pressure Switch... 17 Three Phase Scroll Compressor Start Up... 17 Phase Monitor... 17 Service Hints... 17 Sequence of Operation... 17 Pressure Service Ports... 18 Defrost Cycle... 18 Troubleshooting Solid State Heat Pump Control Troubleshooting Procedure... 20 Checking Temperature Sensor Outside Unit Circuit... 21 Fan Blade Setting Dimensions... 22 Removal of Fan Shroud... 22 Refrigerant Charge... 22 Pressure Tables... 23 Optional ccessories... 24 Figures Figure 1 Unit Dimensions... 3 Figure 2 Fresh ir Damper ssembly... 6 Figure 3 Mounting Instructions... 8 Figure 4 Electric Heat Clearance... 9 Figure 5 Wall Mounting Instructions... 10 Figure 6 Wall Mounting Instructions... 10 Figure 7 Common Wall Mounting Installations... 11 Figure 8 Unit 24V Terminal Board... 12 Figure 9 Compressor Cutoff and Outdoor Thermostat Wiring... 13 Figure 10 Compressor Cutoff and Outdoor Thermostat Wiring... 13 Figure 11 Electric Heat Hold-Off Wiring... 14 Figure 12 Electric Heat Hold-Off Wiring... 14 Figure 13 Defrost Control Board... 19 Figure 14 Fan Blade Setting... 22 Tables Table 1 Electrical Specifications... 4 Table 2 Thermostat Wire Size... 12 Table 3 Wall Thermostat and Subbase Combinations... 16 Table 4 Troubleshooting... 20 Table 5 Fan Blade Dimensions... 22 Table 6 Refrigerant Charge... 22 Table 7 Indoor Blower Performance... 22 Table 8 Recommended Operating Ranges... 22 Table 9 Pressure Table Cooling... 23 Table 10 Pressure Table Heating... 23 Table 11 Optional ccessories... 24
Getting Other Information and Publications These publications can help you install the air conditioner or heat pump. You can usually find these at your local library or purchase them directly from the publisher. Be sure to consult current edition of each standard. National Electrical Code... NSI/NFP 70 Standard for the Installation... NSI/NFP 90 of ir Conditioning and Ventilating Systems Standard for Warm ir... NSI/NFP 90B Heating and ir Conditioning Systems For more information, contact these publishers: CC NSI ir Conditioning Contractors of merica 1712 New Hampshire venue Washington, DC 20009 Telephone: (202) 483-9370 Fax: (202) 234-4721 merican National Standards Institute 11 West Street, 13th Floor New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286 Load Calculation for... CC Manual J or Winter and Manual N Summer ir Conditioning Low Pressure, Low Velocity Duct CC Manual D or System Design for Winter and Manual Q Summer ir Conditioning SHRE merican Society of Heating Refrigerating, and ir Conditioning Engineers, Inc. 1791 Tullie Circle, N.E. tlanta, G 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478 NFP National Fire Protection ssociation Batterymarch Park P.O. Box 9101 Quincy, M 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057 Page 1
WLL MOUNT GENERL INFORMTION HET PUMP WLL MOUNT MODEL NOMENCLTURE MODEL NUMBER SH 26 1 08 X X X X X B CONTROL MODULES CPCITY 30 2-1/2 Ton 36 3 Ton REVISIONS VOLTS & PHSE 230/208/60-1 B 230/208/60-3 C 460/60-3 KW VENTILTION OPTIONS X Barometric Fresh ir Damper (Standard) B Blank-off Plate M Motorized Fresh ir Damper V Commercial Room Ventilator - Motorized with Exhaust E Economizer (Internal) - Fully Modulating with Exhaust R Energy Recovery Ventilator - Motorized with Exhaust P Commercial Room Ventilator - with Exhaust Power Open & Close COLOR OPTIONS X Beige (Standard) 1 White 2 Mesa Tan 4 Buckeye Gray 5 Desert Brown 8 Dark Bronze FILTER OPTIONS X One Inch Throwaway (Standard) W One Inch Washable P Two Inch Pleated COIL OPTIONS X Standard 1 Phenolic Coated Evaporator 2 Phenolic Coated Condenser 3 Phenolic Coated Evaporator and Condenser OUTLET OPTIONS X Front (Standard) NOTE: For 0KW and circuit breakers (230/208 V) or pull disconnects (460 V) applications, insert 0Z in the KW field of model number. Page 2
FIGURE 1 UNIT DIMENSIONS MIS-1744 Page 3
Page 4 TBLE 1 ELECTRICL SPECIFICTIONS Model Rated Volts & Phase No. Field Power Ckts. SINGLE CIRCUIT 3 Minimum Circuit mpacity 1 Maximum External Fuse or Circuit Breaker 2 Field Power Wire Size 2 Ground Wire Size 3 Minimum Circuit mpacity Ckt SH261-0Z 230/208-1 1 22 35 8 10 SH261-B0Z 230/208-3 1 17 25 10 10 SH261-C0Z 460-3 1 10 15 14 14 SH311-0Z 230/208-1 1 26 40 10 10 SH311-B0Z 230/208-3 1 20 25 10 10 SH311-C0Z 460-3 1 11 15 14 14 Ckt B DUL CIRCUIT 1 Maximum External Fuse or Ckt.Breaker Ckt Ckt B 2 Field Power Wire Size Ckt Ckt B 2 Ground Wire Size Ckt Ckt B j Maximum size of the time delay fuse or HCR type circuit breaker for protection of field wiring conductors. k Based on 75 C copper wire. ll wiring must conform to the National Electrical Code and all local codes. l These Minimum Circuit mpacity values are to be used for sizing the field power conductors. Refer to the National Electric Code (latest revision), article 310 for power conductor sizing. CUTION: When more than one field power conductor circuit is run through one conduit, the conductors must be derated. Pay special attention to Note 8 of Table 310 regarding mpacity djustment Factors when more than three conductors are in a raceway.
SHIPPING DMGE Upon receipt of equipment, the carton should be checked for external signs of shipping damage. If damage is found, the receiving party must contact the last carrier immediately, preferably in writing, requesting inspection by the carrier s agent. GENERL The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. The refrigerant system is completely assembled and charged. ll internal wiring is complete. The unit is designed for use with or without duct work. Flanges are provided for attaching the supply and return ducts. These instructions explain the recommended method to install the air cooled self-contained unit and the electrical wiring connections to the unit. These instructions and any instructions packaged with any separate equipment required to make up the entire heat pump system should be carefully read before beginning the installation. Note particularly Starting Procedure and any tags and/or labels attached to the equipment. While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. uthorities having jurisdiction should be consulted before the installation is made. See Page 1 for information on codes and standards. Size of unit for a proposed installation should be based on heat loss calculation made according to methods of ir Conditioning Contractors of merica (CC). The air duct should be installed in accordance with the Standards of the National Fire Protection ssociation for the Installation of ir Conditioning and Ventilating Systems of Other Than Residence Type, NFP No. 90, and Residence Type Warm ir Heating and ir Conditioning Systems, NFP No. 90B. Where local regulations are at a variance with instructions, installer should adhere to local codes. DUCT WORK ny heat pump is more critical of proper operating charge and an adequate duct system than a straight air conditioning unit. ll duct work, supply and return, must be properly sized for the design air flow requirement of the equipment. ir Conditioning Contractors of merica (CC) is an excellent guide to proper sizing. ll duct work or portions thereof not in the conditioned space should be properly insulated in order to both conserve energy and prevent condensation or moisture damage. Refer to Table 10 for maximum static pressure available for duct design. Design the duct work according to methods given by the ir Conditioning Contractors of merica (CC). When duct runs through unheated spaces, it should be insulated with a minimum of one inch of insulation. Use insulation with a vapor barrier on the outside of the insulation. Flexible joints should be used to connect the duct work to the equipment in order to keep the noise transmission to a minimum. 1/4 inch clearance to combustible material for the first three feet (3') of duct attached to the outlet air frame is required. See Wall Mounting Instructions and Figures 4 and 5 for further details. Ducts through the walls must be insulated and all joints taped or sealed to prevent air or moisture entering the wall cavity. ny grille that meets the 5/8 inch louver criteria, may be used. It is recommended that Bard Return ir Grille Kit RG-2 thru RG-5 or RFG-2 thru RFG-5 be installed when no return duct is used. Contact distributor or factory for ordering information. If using a return air filter grille, filters must be of sufficient size to allow a maximum velocity of 400 fpm. NOTE: FILTERS CUTION Some installations may not require any return air duct. metallic return air grille is required with installations not requiring a return air duct. The spacing between louvers on the grille shall not be larger than 5/8 inches. If no return air duct is used, applicable installation codes may limit this cabinet to installation only in a single story structure. 1 inch throwaway filter is supplied with each unit. The filter slides into position making it easy to service. This filter can be serviced from the outside by removing the service door. 1 inch washable filter and 2 inch pleated filter are also available as optional accessories. The internal filter brackets are adjustable to accommodate the 2 inch filter by bending down the tabs to allow spacing for the 2 inch filters. Page 5
FRESH IR INTKE ll units are built with fresh air inlet slots punched in the service panel. If the unit is equipped with the fresh air damper assembly, the assembly is shipped already attached to the unit. The damper blade is locked in the closed position. To allow the damper to operate, the maximum and minium blade position stops must be installed. See Figure 2. ll capacity, efficiency and cost of operation information as required for Department of Energy Energyguide Fact Sheets is based upon the fresh air blank-off plate in place and is recommended for maximum energy efficiency. The blank-off plate is available upon request from the factory and is installed in place of the fresh air damper shipped with each unit. CONDENSTE DRIN plastic drain hose extends from the drain pan at the top of the unit down to the unit base. There are openings in the unit base for the drain hose to pass through. In the event the drain hose is connected to a drain system of some type, it must be an open or vented type system to assure proper drainage. FIGURE 2 BLOWER DMPER SSEMBLY BLDE IS LOCKED CLOSED FOR SHIPPING MIS-938 Page 6
INSTLLTION INSTRUCTIONS WLL MOUNTING INFORMTION 1. Two holes, for the supply and return air openings, must be cut through the wall as shown in Figure 3. 2. On wood-frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration. See Figures 4 and 5. 3. Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installing unit. See Figure 4. MOUNTING THE UNIT 1. These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides. bottom mounting bracket is provided for ease of installation, but it is not required. 2. The unit itself is suitable for 0 inch clearance, but the supply air duct flange and the first 3 feet of supply air duct require a minimum of 1/4 inch clearance to combustible material. If a combustible wall, use a minimum of 28-1/2" x 10-1/2" dimensions for sizing. However, it is generally recommended that a 1 inch clearance is used for ease of installation and maintaining the required clearance to combustible material. The supply air opening would then be 30" x 12". See Figures 3 and 4 for details. 3. Locate and mark lag bolt locations and bottom mounting bracket location. See Figure 4. 4. Mount bottom mounting bracket. If used. 5. Hook top rain flashing under back bend of top. Top rain flashing is shipped attached to the back of the unit on the right side. 6. Position unit in opening and secure with 5/16 lag bolts; use 3/4 inch diameter flat washers on the lag bolts. 7. Secure rain flashing to wall and caulk across entire length of top. See Figure 3. 8. For additional mounting rigidity, the return air and supply air frames or collars can be drilled and screwed or welded to the structural wall itself (depending upon wall construction). Be sure to observe required clearance if combustible wall. 9. On side by side installations, maintain a minimum of 20 inches clearance on right side to allow access to heat strips and control panel, and to allow proper airflow to the outdoor coil. dditional clearance may be required to meet local or national codes. TYPICL INSTLLTIONS See Figure 7 for common ways to install the wallmount unit. WRNING Failure to provide the 1/4 inch clearance between the supply duct and a combustible surface for the first three feet of duct can result in fire causing damage, bodily injury or death. Page 7
FIGURE 3 MOUNTING INSTRUCTIONS MIS-311 Page 8
FIGURE 4 ELECTRIC HET CLERNCE MIS-277 WRNING minimum of 1/4 clearance must be maintained between the supply air duct and combustible materials. This is required for the first three (3) feet of ducting. It is important to insure that the 1/4 minimum spacing is maintained at all points. Failure to do this could result in overheating the combustible material which may result in a fire causing damage, injury, or death. Page 9
FIGURE 5 WLL MOUNTING INSTRUCTIONS SEE FIGURE 3 MOUNTING INSTRUCTIONS WLL STRUCTURE FCTORY SUPPLIED RIN FLSHING. MOUNT ON UNIT BEFORE INSTLLTION SUPPLY IR OPENING SUPPLY IR OPENING SUPPLY IR OPENING RETURN IR OPENING RETURN IR OPENING RETURN IR OPENING BOTTOM MOUNTING BRCKET. MOUNT ON WLL BEFORE INSTLLING UNIT. MIS-548 FIGURE 6 WLL MOUNTING INSTRUCTIONS TTCH TO TOP PLTE OF WLL SEE UNIT DIMENSIONS, FIGURE 1, FOR CTUL DIMENSIONS 1.000 CLERNCE LL ROUND INTERIOR FINISHED WLL OVER FRME SUPPLY DUCT OPENING 1.000 CLERNCE LL ROUND RETURN DUCT OPENING EXTERIOR FINISHED WLL OVER FRME MIS-549 FRMING MTERIL 2 X 4 S, 2 X 6 S ND/OR STRUCTURL STEEL TTCH TO BOTTOM PLTE OF WLL THIS STRUCTURL MEMBER LOCTED TO MTCH STUD SPCING FOR REST OF WLL. SECOND MEMBER MY BE REQUIRED FOR SOME WLLS. Page 10
FIGURE 7 COMMON WLL MOUNTING INSTLLTIONS FREE IR FLOW NO DUCT DUCTED SUPPLY RETURN T UNIT FLSE WLL INSTLLTION CLOSET INSTLLTION MIS-550 Page 11
WIRING MIN POWER Refer to the unit rating plate for wire sizing information and maximum fuse or HCR type circuit breaker size. Each outdoor unit is marked with a Minimum Circuit mpacity. This means that the field wiring used must be sized to carry that amount of current. Depending on the installed KW of electric heat, there may be two field power circuits required. If this is the case, the unit serial plate will so indicate. ll models are suitable only for connection with copper wire. Each unit and/or wiring diagram will be marked Use Copper Conductors Only. These instructions must be adhered to. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. ll wiring muse conform to NEC and all local codes. The electrical data lists fuse and wire sizes (75 C copper) for all models including the most commonly used heater sizes. lso shown are the number of field power circuits required for the various models with heaters. The unit rating plate lists a Maximum Time Delay Relay Fuse or HCR type circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor. The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability, bend the tab located in the bottom left hand corner of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut a padlock may be placed through the hole in the tab preventing entry. WIRING LOW VOLTGE WIRING 230/208V, 1 phase and 3 phase equipment dual primary voltage transformers. ll equipment leaves the factory wired on 240V tap. For 208V operation, reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are: NOTE: Page 12 TP RNGE 240 253 216 208 220 187 The voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition). Nine (9) wires should be run from thermostat subbase to the 24V terminal board in the unit. nine conductor, 18 gauge copper color-coded thermostat cable is recommended. The connection points are shown in Figure 8. Transformer V FIGURE 8 UNIT 24V TERMINL BORD TBLE 2 THERMOSTT WIRE SIZE FL 55 2. 3 IMPORTNT Only the thermostat and subbase combinations as shown above will work with this equipment. The thermostat and subbase must be matched, and the correct operation can be assured only by proper selection and application of these parts. Wire Gauge 20 gauge 18 gauge 16 gauge 14 guage 12 guage Maximum Distance In Feet 45 60 100 160 250
OPTIONL OUTDOOR THERMOSTT PPLICTIONS Since most equipment at the time of manufacture is not designated for any specific destination of the country and are installed in areas not approaching the lower outdoor temperature range, outdoor thermostats are not factory installed as standard equipment, but are offered as an option. There are also different applications for applying outdoor thermostats. The set point of either type of outdoor thermostat application is variable with geographic region and sizing of the heating equipment to the individual structure. Utilization of the heating pplication Data, and the heat loss calculation of the building are useful in determining the correct set points. OPTIONL COMPRESSOR CUTOFF THERMOSTT (SEE FIGURES 9 ND 10) Heat pump compressor operation at outdoor temperatures below 0 F are neither desirable nor advantageous in term of efficiency. n outdoor thermostat can be applied to take the mechanical heating (compressor) off line, and send the (compressor) signal to energize electric heat in its place (to make electric heat first stage heating). This can also be applied to bank the quantity of available electric heat. For example: heat pump operates with 10KW second stage heat once the outdoor thermostat has switched then operates 15KW without the compressor as first stage heat. FIGURE 9 COMPRESSOR CUTOFF THERMOSTT WIRING 4 10KW 1 PH 6 & 9KW 3 PH MIS-409 FIGURE 10 COMPRESSOR CUTOFF THERMOSTT WIRING 15 20KW 1 PH & 3 PH MIS-409 Page 13
ELECTRIC HET HOLD-OFF ( SEE FIGURES 11 ND 12) In other applications, it is desirable to disable the operation of the electric heat until outdoor temperatures have reached a certain design point. This won't allow the electric heat to come on as second stage heating unless the outdoor temperature is below the set point of the outdoor thermostat. This is done to maximize efficiency by utilizing the heat pump to bring the conditioned space temperature up, rather than cycling on the electric heat due a second stage call for heat from the thermostat on start-up coming off a night set-back condition or someone increasing the thermostat set point. (NOTE: Some programmable thermostats do have a built-in time delay for pulling in second stage heat when coming off set-back conditions.) FIGURE 11 ELECTRIC HET HOLD-OFF WIRING 4 10KW 1 PH 6 & 9KW 3 PH MIS-1858 FIGURE 12 ELECTRIC HET HOLD-OFF WIRING 15 20KW 1 PH & 3 PH MIS-1858 Page 14
HET NTICIPTION ll of the thermostats shown in Table 5 have a fixed heat anticipator for stage 1 with no adjustment required. Stage 2 has an adjustable anticipator of the W2 connection and fixed for the W3 connection. Both the W2 and W3 circuits are controlled by the stage 2 bulb. The only heat anticipator that needs to be checked is stage 2 and it should be set to match the load carried by the W2 circuit. The normal factory wiring provides for only one electric heat contactor to be controlled by W2, and the anticipator should be set at.40. If special field wiring is done, it is best to actually measure the load but a good rule is.40 for each heat contactor controlled by W2. THERMOSTT INDICTOR LMPS The red lamp marked Em. Ht. comes on and stays on whenever the system switch is placed in the emergency heat position. The green lamp marked check will come on if there is any problem that prevents the compressor from running when it is supposed to be. EMERGENCY HET POSITION The operator of the equipment must manually place the system switch in this position. This is done when there is a known problem with the unit, or when the green check lamp comes on indicating a problem. COMPRESSOR MLFUNCTION LIGHT ctuation of the green check lamp is accomplished by a relay output from the heat pump control board which is factory installed. ny condition such as loss of charge, high head pressure, etc., that will prevent compressor from operating will cause the green lamp to activate. This is a signal to the operator of the equipment to place system in emergency heat position. Y terminal is the compressor input. B terminal is the reversing valve input. The reversing valve must be energized for heating mode. R terminal is 24 VC hot. C terminal is 24 VC grounded. L terminal is compressor lockout output. This terminal is activated on a high or low pressure trip by the electronic heat pump control. This is a 24 VC output. W2 terminal is second stage heat (if equipped). O1 terminal is the ventilation input. This terminal energizes any factory installed ventilation option. E terminal is the emergency heat input. This terminal energizes the emergency heat relay. NOTE: For total and proper control using DDC, a total of 6 controlled outputs are required (5 if no ventilation system is installed). For proper system operation under Emergency Heat conditions where the compressor needs to be deactivated, the B-W2-E outputs need to be energized. Removing the Y (compressor) signal alone turns the compressor off, but does not activate the additional circuitry embedded in the heat pump for proper and complete operation. Fan Only LOW VOLTGE CONNECTIONS FOR DDC CONTROL Cooling Mode Heat Pump Heating Energize G Energize Y, G Energize Y, G, B LOW VOLTGE CONNECTIONS These units use a grounded 24 volt C low voltage circuit. The R terminal is the hot terminal and the C terminal is grounded. G terminal is the fan input. 2nd Stg Heating w/heat Pump (if employed) Ventilation Emergency Heat Energize G, W2, Y, B Energize G, O1 Energize B, W2, E, G Page 15
TBLE 3 WLL THERMOSTT ND SUBBSE COMBINTIONS Thermostat Subbase Predominant Features 8403-045 (T8411761) - - - 1 stg. cool; 2 stg. heat; Mercury bulb Manual changeover 8403-017 (T874R1129) 8404-009 (Q674L1181) 2 stg. cool; 2 stg. heat; Mercury bulb Manual changeover 1 8403-018 (T874N1024) 8404-010 (Q674F1261) 2 stg. cool; 2 stg. heat; Mercury bulb uto or Manual changeover 2 8403-042 (T8511G1070) - - - 1 stg. cool; 2 stg. heat Electronic Non-Programmable uto or Manual changeover 8403-049 (1F93-380) - - - 2 stg. cool; 2 stg. heat Programmable Electronic uto or Manual changeover j k No automatic changeover position must manually place in heat or cool. Reversing valve remains energized at all times system switch is in heat position (except during defrost cycle). No pressure equalization noise when thermostat is satisfied on either heating or cooling. llows thermostat to control both heating and cooling operation when set in uto position. Reversing valve de-energizes at end of each ON heating cycle. IMPORTNT Both thermostat and subbase combinations shown above incorporate the following features: Man uto fan switch, Off Heat Em. Heat switch, and two (2) indicator lamps; one for emergency heat and one for compressor malfunction. Page 16
STRT UP IMPORTNT INSTLLER NOTE For improved start up performance wash the indoor coil with a dish washing detergent. HIGH PRESSURE SWITCH ll models are supplied with a remote reset high pressure switch. If tripped, this pressure switch may be reset by turning the thermostat off then back on again. THREE PHSE SCROLL COMPRESSOR STRT UP INFORMTION Scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction. However, three phase compressors will rotate in either direction depending upon phasing of the power. Since there is a 50-50 chance of connecting power in such a way as to cause rotation in the reverse direction, verification of proper rotation must be made. ll three phase units incorporate a phase monitor to ensure proper field wiring. See the Phase Monitor section later in this manual. Verification of proper rotation must be made any time a compressor is changed or rewired. If improper rotation is corrected at this time there will be no negative impact on the durability of the compressor. However, reverse operation for over one hour may have a negative impact on the bearing due to oil pump out. NOTE: If compressor is allowed to run in reverse rotation for several minutes, the compressor s internal protector will trip. ll three phase ZR3 compressors are wired identically internally. s a result, once the correct phasing is determined for a specific system or installation, connecting properly phased power leads to the same Fusite terminal should maintain proper rotation direction. Verification of proper rotation direction is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation also results in an elevated sound level over that with correct rotations, as well as, substantially reduced current draw compared to tabulate values. The direction of rotation of the compressor may be changed by reversing any two line connections to the unit. PHSE MONITOR ll units with three phase compressors are equipped with a 3 phase line monitor to prevent compressor damage due to phase reversal. The phase monitor in this unit is equipped with two LEDs. If the Y signal is present at the phase monitor and phases are correct, the green LED will light. If phases are reversed, the red fault LED will be lit and compressor operation is inhibited. If a fault condition occurs, reverse two of the supply leads to the unit. Do not reverse any of the unit factory wires as damage may occur. SERVICE HINTS 1. Caution homeowner to maintain clean air filters at all times. lso, not to needlessly close off supply and return air registers. This reduces air flow through the system, which shortens equipment service life as well as increasing operating costs. 2. Switching to heating cycle at 75 F or higher outside temperature may cause a nuisance trip of the remote reset high pressure switch. Turn thermostat off then on to reset the high pressure switch. 3. The heat pump wall thermostats perform multiple functions. Be sure that all function switches are correctly set for the desired operating mode before trying to diagnose any reported service problems. 4. Check all power fuses or circuit breakers to be sure they are the correct rating. 5. Periodic cleaning of the outdoor coil to permit full and unrestricted airflow circulation is essential. SEQUENCE OF OPERTION COOLING Circuit R-Y makes at thermostat pulling in compressor contactor, starting the compressor and outdoor motor. The G (indoor motor) circuit is automatically completed on any call for cooling operation or can be energized by manual fan switch on subbase for constant air circulation. HETING 24V solenoid coil on reversing valve controls heating cycle operation. Two thermostat options, one allowing uto changeover from cycle to cycle and the other constantly energizing solenoid coil during heating season and thus eliminating pressure equalization noise except during defrost, are to be used. On uto option a circuit is completed from R-W1 and R-Y on each heating on cycle, energizing reversing valve solenoid and pulling in compressor contactor starting compressor and outdoor motor. R-G Page 17
also make starting indoor blower motor. Heat pump heating cycle now in operation. The second option has no uto changeover position, but instead energizes the reversing valve solenoid constantly whenever the system switch on subbase is placed in Heat position, the B terminal being constantly energized from R. thermostat demand for heat completes R-Y circuit, pulling in compressor contactor starting compressor and outdoor motor. R-G also make starting indoor blower motor. PRESSURE SERVICE PORTS High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Pressure tables can be found later in the manual covering all models on both cooling and heating cycles. It is imperative to match the correct pressure table to the unit by model number. DEFROST CYCLE The defrost cycle is controlled by temperature and time on the solid state heat pump control. See Figure 13. When the outdoor temperature is in the lower 40 F temperature range or colder, the outdoor coil temperature is 32 F or below. This coil temperature is sensed by the coil temperature sensor mounted near the bottom of the outdoor coil. Once coil temperature reaches 30 F or below, the coil temperature sensor sends a signal to the control logic of the heat pump control and the defrost timer will start. fter 60 minutes at 30 F or below, the heat pump control will place the system in the defrost mode. During the defrost mode, the refrigerant cycle switches back to the cooling cycle, the outdoor motor stops, electric heaters are energized, and hot gas passing through the outdoor coil melts any accumulated frost. When the temperature rises to approximately 57 F, the coil temperature sensor will send a signal to the heat pump control which will return the system to heating operations automatically. If some abnormal or temporary condition such as a high wind causes the heat pump to have a prolonged defrost cycle, the heat pump control will restore the system to heating operation automatically after 10 minutes. The heat pump defrost control board has an option of 30, 60 or 90 minutes setting. ll models are shipped from the factory on the 60 minute pin. If special circumstances require a change to another time, remove the wire from the 60 minute terminal and reconnect to the desired terminal. The manufacturer's recommendation is for 60 minute defrost cycles. Refer to Figure 13. Use a small screwdriver or other metallic object, or another 1/4 inch QC, to short between the SPEEDUP terminals to accelerate the HPC timer and initiate defrost. Be careful not to touch any other terminals with the instrument used to short the SPEEDUP terminals. It may take up to 10 seconds with the SPEEDUP terminals shorted for the speedup to be completed and the defrost cycle to start. s soon as the defrost cycle kicks in remove the shorting instrument from the SPEEDUP terminals. Otherwise the timing will remain accelerated and run through the 1 minute minimum defrost length sequence in a matter of seconds and will automatically terminate the defrost sequence. There is an initiate defrost jumper (sen jump) on the control that can be used at any outdoor ambient during the heating cycle to simulate a 0 coil temperature. This can be used to check defrost operation of the unit without waiting for the outdoor ambient to fall into the defrost region. By placing a jumper across the SEN JMP terminals (a 1/4 inch QC terminal works best) the defrost sensor mounted on the outdoor coil is shunted out and will activate the timing circuit. This permits the defrost cycle to be checked out in warmer weather conditions without the outdoor temperature having to fall into the defrost region. In order to terminate the defrost test the SEN JMP jumper must be removed. If left in place too long the compressor could stop due to the high pressure control opening because of high pressure condition created by operating in the cooling mode with outdoor fan off. Pressure will rise fairly fast as there is likely no actual frost on the outdoor coil in this artificial test condition. There is also a 5 minute compressor time delay function built into the HPC. This is to protect the compressor from short cycling conditions. In some instances it is helpful to the service technician to override or speed up this timing period, and shorting out the SPEEDUP terminals for a few seconds can do this. Page 18
FIGURE 13 DEFROST CONTROL BORD MIS-1191 Page 19
TROUBLESHOOTING SOLID STTE HET PUMP CONTROL TROUBLESHOOTING PROCEDURE 1. Turn on C power supply to indoor and outdoor units. 2. Turn thermostat blower switch to fan on. The indoor blower should start. (If it doesn t, troubleshoot indoor unit and correct problem.) TBLE 4 TROUBLESHOOTING 3. Turn thermostat blower switch to auto position. Indoor blower should stop. 4. Set system switch to heat or cool. djust thermostat to call for heat or cool. The indoor blower, compressor, and outdoor fan should start. NOTE: If there was no power to 24 volt transformer, the compressor and outdoor fan motor will not start for 5 minutes. This is because of the compressor short cycle protection. Symptom Compressor contactor does not energize (heating or cooling) Fan outdoor motor does not run (cooling or heating except during defrost) Reversing valve does not energize (heating only) Unit will defrost not go (heating only) into Unit will not come out of defrost (heating only) Possible Causes Control circuit wiring C ompressor lock out 1. Compressor short cycle protection Heat pump defective control Contactor defective Power phasing correct Motor defective Motor capacitor defective Heat pump defective not control Reversing valve solenoid coil defective Heat pump defective control Temperature sensor or heat pump control defective Temperature sensor or heat pump control defective What to Check Check for R connectio at uni t and 24 volt between R - C 2. Check for 24V between L1-C on heat pump control. Check across high pressure switch Check for 24 V between CC-C and Y-C on heat pump control. Check all other possible causes. Manual 2100-065 Check for winding. open or shorted coil Check for red LED on phase monitor (3 phase units only). Check for open or motor winding. shorted Check capacitor ratng. Check for open or shorted capacitor. Check across fan relay on heat pump control (Com-NC). Run R connection to pump control. 1. 2. How to Dheck or Repair outdoor unit to power heat If no voltage between L1-C, turn thermostat off and on again to reset high pressure switch. If high pressure switch is open and will not reset, replace high pressure switch. If not voltage between CC-C, jumper speed up terminal, and within 10 seconds power should appear between CC-C. Remove speed up jumper after 10 seconds. Replace heat pump Replace contactor. control. Switch two power leads to the unit. Replace motor. Replace capacitor. Replace heat pump C heck for open or shorted coil. Replace solenoid Coil. Check for 24V between RV-C and B-C. Disconnect temperature sensor from board and jumper across speed up terminals and sen jump terminals. This should caruse the unit to go through a defrost cycle within one minute. Jumper across speed up terminals. This should cause the unit to come out of defrost within one minute. 1. 2. 1. 2. 1. 2. control. Check control circuit wiring. Replace heat pump control. If unit goes through defrost temperature sensor. cycle, replace If unit does not go through defrost cycle, replace heat pump control. If unit comes out of defrost cycle replace temperature sensor. If unit does not come out of defrost cycle, replace heat pump control. Page 20
CHECKING TEMPERTURE SENSOR OUTSIDE UNIT CIRCUIT 1. Disconnect temperature sensor from board and from outdoor coil. 2. Use an ohmmeter and measure the resistance of the sensor. lso use ohmmeter to check for short or open. 3. Check resistance reading to chart of resistance use sensor ambient temperature. (Tolerance of part is ± 10%) 4. If sensor resistance reads very low, then sensor is shorted and will not allow proper operation of the heat pump control. 5. If sensor is out of tolerance, shorted, open, or reads very low ohms then it should be replaced. TEMPERTURE F VS RESISTNCE R OF TEMPERTURE F R F R F R 196871 25.0 39898 75.0 190099 26.0 38757 76.0 183585 27.0 37652 77.0 177318 28.0 36583 78.0 171289 29.0 35548 79.0 165487 30.0 34545 80.0 159904 31.0 33574 81.0 154529 32.0 32634 82.0 149355 33.0 31723 83.0 144374 34.0 30840 84.0 139576 35.0 29986 85.0 134956 36.0 29157 86.0 130506 37.0 28355 87.0 126219 38.0 27577 88.0 122089 39.0 26823 89.0 118108 40.0 26092 90.0 114272 41.0 25383 91.0 110575 42.0 24696 92.0 107010 43.0 24030 93.0 103574 44.0 23384 94.0 100260 45.0 22758 95.0 97064 46.0 22150 96.0 93981 47.0 21561 97.0 91008 48.0 20989 98.0 88139 49.0 20435 99.0 85371 50.0 19896 100.0 82699 51.0 19374 101.0 80121 52.0 18867 102.0 77632 53.0 18375 103.0 75230 54.0 17898 104.0 72910 55.0 17434 105.0 70670 56.0 16984 106.0 68507 57.0 16547 107.0 66418 58.0 16122 108.0 64399 59.0 15710 109.0 62449 60.0 15310 110.0 60565 61.0 14921 111.0 58745 62.0 14544 112.0 56985 63.0 14177 113.0 55284 64.0 13820 114.0 53640 65.0 13474 115.0 52051 66.0 13137 116.0 50514 67.0 12810 117.0 49028 68.0 12492 118.0 47590 69.0 12183 119.0 46200 70.0 11883 120.0 44855 71.0 11591 121.0 43554 72.0 11307 122.0 42295 73.0 11031 123.0 41077 74.0 10762 124.0-25.0-24.0-23.0-22.0-21.0-20.0-19.0-18.0-17.0-16.0-15.0-14.0-13.0-12.0-11.0-10.0-9.0-8.0-7.0-6.0-5.0-4.0-3.0-2.0-1.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 10501 10247 10000 9760 9526 9299 9077 8862 8653 8449 8250 8057 7869 7686 7507 7334 7165 7000 6840 6683 6531 6383 6239 6098 5961 5827 5697 5570 5446 5326 5208 5094 4982 4873 4767 4663 4562 4464 4367 4274 4182 4093 4006 3921 3838 3757 3678 3601 3526 3452 Page 21
FN BLDE SETTING DIMENSIONS Shown in Figure 14 are the correct fan blade setting dimensions for proper air delivery across the outdoor coil. ny service work requiring removal or adjustment in the fan and/or motor area will require that the dimensions below be checked and blade adjusted in or out on the motor shaft accordingly. FIGURE 14 FN BLDE SETTING IRFLOW REFRIGERNT CHRGE The correct system R-22 charge is shown on the unit rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line temperature (6 from compressor) as shown in Table 6. Model SH261 SH311 TBLE 6 REFRIGERNT CHRGE Rated irflow 800 800 95 F OD Temperature 67-69 66-68 82 F OD Temperature 64-66 64-66 The suction line temperatures in Table 6 are based upon 80 F dry bulb / 67 F wet bulb (50% R.H.) temperature and rated airflow across the evaporator during cooling cycle. MIS-1424 TBLE 5 FN BLDE SETTING Model SH261 SH311 Dimension 1.25 REMOVL OF FN SHROUD 1. Disconnect all power to the unit. 2. Remove the screws holding both grilles, one on each side of unit, and remove grilles. 3. Remove screws holding fan shroud to condenser and bottom. Nine (9) screws. 4. Unwire condenser fan motor. 5. Slide complete motor, fan blade, and shroud assembly out the left side of the unit. 6. Service motor/fan as needed. 7. Reverse steps to reinstall. "" TBLE 7 INDOOR BLOWER PERFORMNCE CFM @ 230V E.S.P. In H.0.1.2.3 2 O Low Speed Dry Coil 950 840 750 - - - SH261, SH311 Wet Coil 900 800 650 - - - High Speed Dry Coil 1050 900 750 600 Wet Coil 1000 850 700 550 TBLE 8 RECOMMENDED OPERTING RNGES Model SH261 SH311 Rated CFM * 800 800 Rated ESP *.10.10 Recommended irflow Range 600-900 600-900 * Rated CFM and ESP on high speed tap. Page 22
TBLE 9 PRESSURE TBLE COOLING Model SH261 SH311 Return ir Temperature 75 deg. DB 62 deg. WB 80 deg. DB 67 deg. WB 85 deg. DB 72 deg. WB 75 deg. DB 62 deg. WB 80 deg. DB 67 deg. WB 85 deg. DB 72 deg. WB ir Temperature Entering Outdoor Coil F Pressure 75 80 85 90 95 100 105 110 115 Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side Low Side High Side 78 200 83 205 86 212 73 190 78 195 81 202 79 215 84 221 87 229 74 205 79 210 82 217 80 232 86 238 89 246 75 220 80 226 83 234 81 251 87 257 90 266 76 237 81 243 84 252 81 269 87 276 90 286 77 254 82 260 85 269 82 290 88 297 91 307 78 272 83 279 86 289 83 312 89 320 92 331 78 291 83 298 86 308 83 334 89 343 92 355 79 309 84 317 87 328 84 359 90 368 93 381 79 330 84 338 87 350 TBLE 10 PRESSURE TBLE HETING Return ir Model Temperature S H261 70 deg. S H311 70 deg. ir Temperature Entering Outdoor Coil F Pressure 0 5 10 15 20 25 30 35 40 45 50 55 60 65 Low Side High Side Low Side High Side 12 152 19 184 17 159 21 185 22 165 24 187 27 172 27 190 32 178 30 195 37 185 34 201 42 192 38 208 48 198 43 216 83 205 48 226 58 212 54 237 63 219 60 249 69 226 67 263 74 233 74 278 80 240 82 294 Low side pressure ± 2 PSIG High side pressure ± 5 PSIG Tables are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operating charge being in the system, the charge should be removed, system evacuated and recharged to serial plate instruction. Page 23
TBLE 11 OPTIONL CCESSORIES Model Description BOP-3 Blank Off Plate X X X X X X BFD-3 Barometric Fresh ir Damper X X X X X X MFD-3 Motorized Fresh ir Damper X X X X X X WERV-3 Energy Recovery Ventilator X X X X WERV-C3 Energy Recovery Ventilator X X CMH-3 Low Pressure Control (LPC) X X X X X X CMH-7 Low mbient Control (LC) X X X X CMH-9 LC + LPC X X X X CMH-14 Outdoor Thermostat (ODT) X X CMC-15 Start Kit (SK) X X SH261- SH261-B SH261-C SH311- SH311-B SH311-C Page 24